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Studio Scale Long Range Shuttle Surak - Printable Version

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Studio Scale Long Range Shuttle Surak - dbhs - 02-29-2012

My new project is a scratch-built Studio Scale replica of the Vulcan Shuttle Surak, officially known as the Long Range Shuttle. This project has been in research, planning, and development for over two years now and I'm really excited to have it off the drawing boards and taking physical form.

First off I'd like to give a huge -HUGE- thank you to all of the people who helped me to make this project a reality. In addition to help from friends on the modeling forums a lot of time also went into finding information from people and sources not available on the boards. Although time consuming, it paid off in spades. The help from all of these generous people are what made this project a reality and I am very grateful.

This photo is a screen cap, of course, and shows the model as it appeard in the movie. My goal is to duplicate the original filming model, as it actually appeared, in all its glorious 'pinkness'.

I'll be posting a complete build diary on my website but will post updates as I go.

[Image: VS-000.JPG]


I'm starting with the nacelles first as they seem to be the trickiest part of the model. My first thought on the nacelles was that the structure inside would be critical. They are long and slender and supported on one end only. They also would need to be as light-weight as possible.

To create the tapered profile I decided to generate a series of ribs each one slightly different as the 6-sided cross section tapered down the length. Perpendicular to the ribs I'm using a square aluminum tube. The ribs are about an inch apart with additional ones added in for specific details. There's about 50 ribs total along the length.

After drawing profiles of the nacelles in AutoCAD I generated a series of cross-sectinal ribs. I'm cutting the ribs out of 1/8" thick cast-acrylic with a laser cutter. To do this economically I got a membership at the TechShop in San Francisco. The TechShop is a membership-based workshop with just about every tool you can imagine. They're fairly new and opening up new locations all over the country. They have 4 laser cutters at the SF location. They also have a really nice vacuum former and plastic bender which will come in handy later on.

Getting the first few ribs on square to the tube was critical. With the tube clamped down I used these machinist's 1-2-3 blocks to align the ribs and hold them in place while gluing.

Between each rib are three spacers parallel to the tube (top, bottom, and side).

[Image: VS-006.JPG]


A bit more. Here you can see holes I added to the ribs where the wiring for the lights will run through.

[Image: VS-007.JPG]


Here's the progress so far in front of the drawing and a Pepsi can for scale. The nacelles are a little under 3 feet long.

[Image: VS-010.JPG]


This is a prototype test for the sled cross piece. It's cut from 1/4" cast acrylic. It's pretty rigid and should be plenty strong to support the nacelles. On the original model this piece was aluminum plate which was necessary to support the nacelles that were wood covered with plastic sheeting. Bending this to the right shape will be complicated and I'm assuming it will take a few tries to get it right. This will be the first test piece.

[Image: VS-011.JPG]

Thanks for looking.

-Doug


RE: Long Range Shuttle - Surak - Cylon-Knight - 02-29-2012

WOW!
Shock and Awe. Love, love love it!


RE: Long Range Shuttle - Surak - JAWS - 02-29-2012

Yeah impressive acrylic work Doug.
Thats hard stuff to work with.


RE: Long Range Shuttle - Surak - dbhs - 02-29-2012

Thanks guys !
Yeah the acrylic is a bit of a pain. One thing I like about it is that it's compatible with styrene and can use the same solvent glue.


RE: Long Range Shuttle - Surak - dbhs - 03-04-2012

I posted an update on my site. Here are a few of the new pics.

[Image: VS-014.JPG]

[Image: VS-018.JPG]







RE: Long Range Shuttle - Surak - Wombat - 03-23-2012

A long time in the planning this one and it must feel good finally seeing it all come together there.

Looking fantastic btw!

Bet theres some drool under some of them Trekie fanatics out there from seeing this!!! LOL

Awesome work and i mean just that. I'm not a fan but i can see serious thought has gone into all this. Up there with some of the best builds at this stage from what i can see of it.




RE: Long Range Shuttle - Surak - JAWS - 03-27-2012

Great work Dougy. Any updates?


RE: Long Range Shuttle - Surak - dbhs - 03-28-2012

Thanks for asking, Jase. This one is on hold now. I've got too much stuff going on in life to get any modeliing done for a while. I have a few pics that I haven't posted yet of the last progress I made. Maybe in few days I'll get those up.

Thanks for the comments, Phil. I've come really close to finding a better way to deal wth the lighting but can't work on it now. Going to try skinning this with clear styrene instead of the standard white. I found a source that sells it just under a 1/16" thick (3/64").


RE: Long Range Shuttle - Surak - swhite228 - 04-24-2012

Just something I found that might help out anyone working on this.




[attachment=11029]

It's the patent for the shuttle. I havent found one for the warp sled.


RE: Long Range Shuttle - Surak - dbhs - 04-24-2012

Thanks for posting these. I remember seeing these a while back. They are certainly interesting to look at but unfortunately not useful for the SS build. The language in the description is interesting. It seems this is more to protect against unlicensed toy production than anything else.


RE: Long Range Shuttle - Surak - dbhs - 04-27-2012

Getting caught up with posting my previous progress.

This is the line bender I'm using at the TechShop. It makes bending the acrylic a piece of cake.
[Image: VS-019.JPG]

And the adjustable fence for bending to the correct angle.
[Image: VS-020.JPG]

The main challenge with bending the 1/4" acrylic is that it tends to want to bend to a particular radius every time and not the right radius. The radius it wants to bend to is too small. On some 1/8" acrylic test pieces I realized that the outside radius of those bends is just about right for the inside radius on the 1/4" acrylic. So I made a form to bend over to force the 1/4" acrylic into the right shape. These photos show that process.

[Image: VS-023.JPG]
[Image: VS-022.JPG]
[Image: VS-021.JPG]



RE: Long Range Shuttle - Surak - JAWS - 04-27-2012

Looking good Dougy.


RE: Long Range Shuttle - Surak - dbhs - 04-28-2012

This is a mockup with the first test piece of the 1/4" acrylic just to get a sense of the size of it. The 2 nacelles are test pieces and both starboard nacelles.

It's really cool seeing it take shape finally. I love the size of it. Going to be a lot of fun to paint and weather at this scale.

[Image: VS-024.JPG]

[Image: VS-025.JPG]

[Image: VS-026.JPG]

[Image: VS-027.JPG]


RE: Long Range Shuttle - Surak - Wombat - 04-28-2012

It's good to see once again that you are getting things sorted out there.Smile


RE: Long Range Shuttle - Surak - Wombat - 05-01-2012

Not that you really need any motivation...Wink


RE: Long Range Shuttle - Surak - dbhs - 05-02-2012

Thanks, Phil. Mostly just caught up with pictures from 2 months ago. I've got one more set to post. Fortunately I just got my modeling stuff back a few days ago and will be setting up the new workspace soon.


RE: Long Range Shuttle - Surak - Wombat - 05-02-2012

That really is fantasic news, Doug!!

Most happy to hear that mate!

You know i hadn't seen that picture i posted before ( I don't get out much as ya can tell) but it's the first picture that i actually like the look of with this subject. Don't look half bad really!




RE: Long Range Shuttle - Surak - dbhs - 05-03-2012

Great reference. Thanks.

This is a great picture and really highlights just how much detail the studio model has. The paint work and decals are a huge part of the detailing and are pretty complicated. Gonna be fun !

I think that I'm looking forward to the painting of this model more than anything else.


RE: Long Range Shuttle - Surak - Wombat - 05-03-2012

That picture shows a side of it i hadn't seen before and i actually like it if nothing else.

Was flicking through some old Starlog books when i came across it and it caught my attention straight away. Won't be too long and it'll be your head in that pictures instead of Andy's. LOL

I think it'll be interesting to see how it comes out but it'll be a lil tricky working out which shade is which with the colours being so close. Having some good colour reference may help you a lil there though. I remember you talking about that before and i think i can see where you was coming from. End of the day it's gonna be a fantastic looking piece if it turns out looking anything like that.


RE: Studio Scale Long Range Shuttle Surak - dbhs - 07-06-2012

So.....This is an update but not in the way I'd prefer.

These are the last few pictures from way back right after testing out the lighting systems. The ends of the nacelles are super tight but the LEDs fit. I could go with smaller LEDs but I really like the color temperature and intensity of these LEDs and haven't found something comparable in 3mm size. These do fit so it will be fine. There's 2 LED's at each light cluster to get the steady-on and stobe effect as seen on film. I know the original didn't work exactly like that but I want the lights to function as seen on film because it just looks so cool.

This mock up is skinned with 1/16" white styrene and then with a layer of .015" clear styrene. The clear is so I can mask off and get clean rectangular light openings. The clear styrene is too thin to use effectively. It tends to bubble up and warp if just slightly too much glue is used. I finally found a source of clear styrene in 1/16" thickness which will be perfect and allow me to just skin this thing one time.

Hopefully I'll be back on this one in a few months.

[Image: VS-028.JPG]
[Image: VS-029.JPG]
[Image: VS-030.JPG]
[Image: VS-031.JPG]
[Image: VS-032.JPG]


RE: Studio Scale Long Range Shuttle Surak - Wombat - 07-06-2012

You tease! Wheres the lit shot?


Even if it some progress from earlier it looks like it'll work just fine as you've said. This was coming along nicely, hopefully you'll be able to get back to it soon once everything is sorted out.


RE: Studio Scale Long Range Shuttle Surak - dbhs - 09-11-2014

And 2 years later..... back at it again......

[Image: photo%25201.JPG]

[Image: photo%25202.JPG]

[Image: photo%25203.JPG]

[Image: photo%25204.JPG]

[Image: photo.JPG]




RE: Studio Scale Long Range Shuttle Surak - star-art - 09-11-2014

Wow, Doug! I had never seen this thread before today. Very, very impressive work!!! Smile


RE: Studio Scale Long Range Shuttle Surak - JAWS - 09-11-2014

Impressive



RE: Studio Scale Long Range Shuttle Surak - Tsophika - 09-11-2014

That is some nice acrylic work.

C


RE: Studio Scale Long Range Shuttle Surak - MonsieurTox - 09-12-2014

Wow that's wonderful !!


RE: Studio Scale Long Range Shuttle Surak - dbhs - 09-12-2014

Thanks guys. It's going well, although slowly. Drilling out the big holes in the 1" thick acrylic was scary on my rusty old drill press. I'm working on wiring up all the lights now. Hopefully some new pics soon.


RE: Studio Scale Long Range Shuttle Surak - dbhs - 09-17-2014

And a little more with the wiring getting started....

[Image: photo%25201.JPG]

[Image: photo%25202.JPG]


RE: Studio Scale Long Range Shuttle Surak - MonsieurTox - 09-17-2014

These acrylic parts look so nice ! Very nice !

Are you going to paint it pink like the original model or grey like in the movie ?


RE: Studio Scale Long Range Shuttle Surak - MonsieurTox - 09-17-2014

Sorry I had not read the first post haha or I did years ago Smile
It will be pink then !


RE: Studio Scale Long Range Shuttle Surak - roboterkampf - 09-17-2014

What a great and under represented subject to model! I love the acrylic!!


RE: Studio Scale Long Range Shuttle Surak - dbhs - 09-18-2014

Thanks guys. Yes, pink. Way too pink.
Working with acrylic is fun but challenging. Even with all the planning I've done I still manage to keep the dremel warm.


RE: Studio Scale Long Range Shuttle Surak - dbhs - 10-05-2014

Another small update. Wish I had more time.

Almost impossible to see detail in the clear acrylic but there's a few forward pieces of hull on.
[Image: photo%25201.JPG]

Forward light test
[Image: photo%25202.JPG]

8 LEDs on each of the main engine lights.
[Image: photo%25203.JPG]

Light test
[Image: photo%25204.JPG]

Unruly wires. These will get tidied up after testing out the flashing circuits.
[Image: photo%25206.JPG]

[Image: photo%252010.JPG]

Thanks for looking



RE: Studio Scale Long Range Shuttle Surak - dsp5500 - 10-05-2014

Lovely detailed work.


RE: Studio Scale Long Range Shuttle Surak - dbhs - 10-07-2014

Thanks.
Once the electronics is done and tested I'll be able to start closing it up.


RE: Studio Scale Long Range Shuttle Surak - dbhs - 11-16-2014

I made a little more progress on this one with the shuttle's body panels and rear hatch. In these photos all the panels are just test fit. They won't be glued on until all of the wiring inside is complete. I should be getting my flashing circuits soon and then the electronics can proceed. Thanks for looking.

[Image: IMG_6200.JPG]

[Image: IMG_6201.JPG]

[Image: IMG_6203.JPG]

[Image: IMG_6204.JPG]

[Image: IMG_6205.JPG]

And one with a few of the kit parts for reference.
[Image: IMG_6199.JPG]


RE: Studio Scale Long Range Shuttle Surak - LeeS - 11-16-2014

Amazing!!!


RE: Studio Scale Long Range Shuttle Surak - Guy Cowen - 11-17-2014

Amazing stuff Doug, if you don't mind me asking whats the kit part at the rear of the last pic thats shares with the Vader X1, no worries if your not able to share, its one of those cool parts thats little seen ?

Great build as always


RE: Studio Scale Long Range Shuttle Surak - dbhs - 11-17-2014

Thanks for the comments.
That part is from the Renwal 1:200 Polaris Nuclear Sub.


RE: Studio Scale Long Range Shuttle Surak - Guy Cowen - 11-17-2014

Well I never, never even heard of it, awesome stuff again and thank you for sharing it. Always wandered what it was, very much appreciated thanks


RE: Studio Scale Long Range Shuttle Surak - dbhs - 11-17-2014

There's an old thread at RI that has a lot of reference info on the Surak. http://www.resinilluminati.com/showthread.php?t=6877
That sub kit is hard to find and expensive. You need 4 of them for the one model. I had good castings made of mine to use for 3 of them as I couldn't see paying for 4 kits just for 1 part each.


RE: Studio Scale Long Range Shuttle Surak - dbhs - 12-09-2014

Dan from Lightbenders built a light circuit board that allows me to control the strobe timing and sequencing on 5 separate circuits each for the sled and shuttle strobe lights and reaction control jets. In addition to the flashing lights there will be separate circuits for the engines, running lights, and shuttle docking lights. I'm really stoked about getting to this point so I can get all the electronics installed and finish installing all of the body panels.

Below is a link to the youtube video.
https://www.youtube.com/watch?v=SY2hA50HoJQ


RE: Studio Scale Long Range Shuttle Surak - swhite228 - 12-12-2014

(11-17-2014, 11:34 AM)dbhs Wrote: There's an old thread at RI that has a lot of reference info on the Surak. http://www.resinilluminati.com/showthread.php?t=6877
That sub kit is hard to find and expensive. You need 4 of them for the one model. I had good castings made of mine to use for 3 of them as I couldn't see paying for 4 kits just for 1 part each.

The sub kit was reissued this year by Revell USA under the Renwal brand .and should be easy to find at this point.  I got 2 of them from Hobbytown in March.


RE: Studio Scale Long Range Shuttle Surak - dbhs - 12-30-2014

Lights installed in the shuttle. Hull panels and light blocking in progress.

[Image: surak%2B1.jpg]

[Image: surak%2B2.JPG]


RE: Studio Scale Long Range Shuttle Surak - JAWS - 01-04-2015

Wow Doug! That's some work you've been at! Looking incredible.


RE: Studio Scale Long Range Shuttle Surak - dbhs - 05-16-2015

Haven't updated here for a while. Here's a quick update.....

[Image: 2015-03-10.jpg]

[Image: 11270197_1614779835429410_3205734445651766275_o.jpg]


RE: Studio Scale Long Range Shuttle Surak - dbhs - 06-28-2015

The top and front of the sled are done except for some of the side panels. I made a video of the lighting.

https://youtu.be/yy0oCtAERSE


RE: Studio Scale Long Range Shuttle Surak - Wombat - 06-30-2015

You know if you'd made it bigger you would have been able to fit all that crap in there a lot easier..lol

Good to see a lil bit of action happening with this again. You must be really dieing to get this to the paint stage but as you know these good things do take time. I think it's good that you are just tinkering around with it again there. One thing will lead to another and soon you'll be at that paint stage. Nice bit of work mate! :-)


RE: Studio Scale Long Range Shuttle Surak - dbhs - 07-18-2015

Thanks Phil. Yeah, it's getting there little by little. I'm working on the putty and sand phase on a lot of it now. I want to get the bulk of that done before applying the small details that get in the way.


RE: Studio Scale Long Range Shuttle Surak - dbhs - 08-18-2015

A long overdue update. Real life has kept me away from most online activities for the last few weeks but I've made some time for this build little by little. Beside repeated sanding and puttying of the nacelles and shuttle and adding the details to the front of the nacelles a major hurdle was past this weekend. I finally attached the nacelles to the upper part of the sled. It's finally starting to look like the real thing now.